3D printed propellant-based propulsion systems for superior mission capability and affordability

Firehawk Aerospace (Firehawk) will demonstrate advanced 3D printed propulsion systems utilizing additively manufactured propellants to enhance the capabilities and affordability of solid rocket motors (SRMs) for the Department of the Air Force. Firehawk’s unique solution marries the advancements made in additive manufacturing (AM) and engineering design principles with modern rocket science resulting in novel solid rocket motor solutions, including next-generation hybrid rocket engines with printed fuel grains, novel monopropellant thruster system architectures, and solid rocket motor propellant grains under active development. Firehawk's innovative approach leverages commercially available off-theshelf (COTS) additive manufacturing equipment to produce thermoplastic-based propellants, which offer significant cost, logistical, and performance advantages over traditional manufacturing methods. This proposal is focused on the use of Firehawk’s proprietary additive manufacturing processes to optimize novel solid rocket motor propellant formulations compatible with conventional AM systems as an alternative to those cast and cured methods employed today. The program will involve the characterization and optimization of these propellants, focusing on achieving performance metrics that meet or exceed conventional SRM formulations while significantly reducing production times and costs. Key technical activities include thermal stability testing,  sensitivity characterization, extrusion trials, and subscale performance testing, culminating in static-fire tests of a 5” diameter propulsion system. Thermal stability and sensitivity testing will be performed where appropriate according to standard DoD testing methodologies. AM-produced solid propellant grains will be tested in a Firehawkdeveloped small-scale solid rocket motor ground-test article to evaluate the performance of these propellant formulations under representative motor operating conditions. Successful completion of these efforts will further demonstrate the viability of Firehawk’s thermoplastic-based solid propellants for use with conventional AM systems and characterize the performance of these formulations in a 5” class representative weapon system analog design.